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Confidential | Copyright © VAPCO Engineers Pvt. Ltd.

Building Energy Efficient Technology

VAPCO ENGINEERS PVT. LTD.

WELCOMES

ALL DELEGATES OF

UPDA

9th SEPTEMBER 2016


Content

VAPCO - INTRODUCTION

OFFERINGS & EXPERIENCE

CHALLENGES & OPPORTUNITIES

VAPCO SOLUTIONS

BUSINESS MODEL

RECENT CASE STUDIES


VAPCO in a snapshot

• Provide sustainable & greener solutions in the form ofEngineering services & EPC solutions in the selectedprocess industries.

• Suggest solutions for enhancement of operationalefficiency.

• Offers Technologies & systems which are :

• more INCLUSIVE in nature.

• Provide RIGHT & SUSTAINABLE solutions & enhancegrowth of our CUSTOMERS

Genesis:

Explore, Develop & Design green ways of protecting ourSurroundings, People and The Nature.

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VAPCO in a snap shot

We aim to be recognized as CUSTOMER CENTRIC & FRIENDLY organization withgoal of moderate growth, profitability and maintaining our sense of humour.

To be recognized as important & preferred EPCplayer in the Ethanol, Starches and allied industries andcreate VALUE for our customers & employeesVISION

VAPCO is committed to provide sustainable & environmentfriendly designs & EPC solutions in the field of Ethanol, Starch,Chemicals & Pharma Industries.

We view ourselves as partner with our customers, our employee,our community & environment.

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Our Team

Promoted by Technocrats with extensive experience in the field of process industry in terms of design, engineering & operations of plants

Professional set up with focus on “ENGINEERING SOLUTIONS”

Management team with clear vision & thoughts in place

Executive team members with HANDS ON experience in selecteddomains

Proven Project & Construction Management & implementation team

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Fabrication works

1. Mechanical design & fabrication

conforming to international

standards such as ASME, TEMA,

DIN, IS, IBR for equipment like

distillation columns, heat

exchangers, tanks & vessels.

2. Fabrication of pressure vessels as per

ASME for ‘U’ stamping.

3. Manufacturing facility at Pune having

area of 10000 feet² with covered shed and

separate handling facilities for Stainless

steel and Carbon steel material.

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VAPCO – Journey till Today…

2011

Establishment

2012• First Contract for

45 KLPD

Distillation plant

2012

2014

2013

2015

2013• First Distillation plant

commissioned

• 2 Overseas contracts

received

• Dryer orders for Starch

Industry

• 45 KLPD Grain based

distillery order

2014• Canada Re-distillation

plant commissioned

• First Integrated Evaporator

order

• First DDGS Dryer Order

• Commissioning of Starch,

Fiber & Gluten Dryers

2015 • Commissioning of 1st Steam less

Integrated Evaporation

• DDGS Dryer Commissioned

• Ethiopia Mini-Distillery

commissioned

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2016

2016 • Commissioning of 50 KLPD

MSDH Plant

• 170 KLPD Grain plant completed

• 40 KLPD MSDH plant under

execution

• Development of BSW

Evaporation process condensate

stripping unit – Under trial Run

• 2 BSW Evaporation plants :

Under Erection


Content




VAPCO SOLUTIONS

BUSINESS MODEL

RECENT CASE STUDIES


Our Industry focus

Major Sectors :

• Ethanol from various raw materials such as Molasses, Grains, Cassava, Cane Juice etc. for producing:

– Rectified Spirit

– Extra Neutral Alcohol

– Absolute Alcohol

• Starch & derivatives plant for producing various base & modified starches

• Standalone Evaporation & Drying systems for Ethanol, Starches, Chemical & Pharma Industries

• Zero Liquid discharge systems for various process industries

Offerings :

• Engineering Services:

– Basic

– Detailed

– Procurement

– Project Management

• Lump sum Turnkey packages :

– Complete plants

– Process units

– Battery limit plants

• Studies & Audits of existing plants for

– improving efficiencies & debottlenecking

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Multi Disciplinary Engineering

Plant Engineering

Process

Mechanical

Civil/ Structural

Electrical

Instrumentation

Piping Engg.

Multi Disciplinary Customized engineering

Overall optimizati

on and RIGHT

SIZING of the

equipment

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Present experiences…

Ethanol

Rich Experience in Molasses as

well as Grains as feed stock

From Technical audits to supply of Process

Packages to TURNKEY projects.

Domestic as well as

international experience

Stand alone package units for :

• Milling, Liquefaction & Fermentation

• Distillation

• Evaporation with drying systems

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Present experiences…

Starch & Derivatives

Gaining Experience

through Maize as

major raw materials

From Technical audits to supply of Process

Packages to TURNKEY projects.

Domestic experience

Stand alone package

units for :

• Drying of Fiber, Germ, Gluten and starch

• Evaporation Systems

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Present experience…

Dryers

Rich Experience in Maize & other

grains as feed stock

Products handled

Germ

Fiber

Starch

Gluten

Multiple choice of

Drying technologies

Types of Dryers

Rotary Steam Tube Bundle dryers

Flash dryers

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Present experience…

DDGS Dryers

Supply of Rotary Steam Tube

Bundle Dryer at two Distilleries

Feed Stocks

HandledSyrup

Wet Cake

Operation at Steam Pressure

of 3.50 kg/cm2(g)

Features:Runs on conduction principle

Fixed shell & rotating tubebundle

- good material contact

- Better product

- Consumes less electricity

Properly sized and spacedbaffles provides proper supportto steam tubes

Provision for expansion of tubebundle prevents stress build-upand ensures longer life

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Content




VAPCO SOLUTIONS

BUSINESS MODEL

RECENT CASE STUDIES


General Concerns & Problems

• Lower Recoveries

• Higher steam consumption

• Inferior product quality

• Higher Impure Spirit Cut

• Non utilization of syrup

• Evaporation of spent wash to the RIGHT SOLIDS

• Spent wash incinerator working

• Inadequate quality of DDGS

• How to approach ZERO DISCHARGE?

• Process Streams

• Non Process streams

• Steam & Power Balance

TECHNICAL:

• Higher Project Investments

• Higher Operating Costs

• Viability of expansions:

• Green

• Brown

FINANCIAL:

• Skill sets of Team

• Operational philosophy

• Manual vsAutomation

OPERATIONAL

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Specific Challenges & Opportunities

Grain Based Plants / Conversion

• Optimum usage of existing infrastructure

• Reduction in energy consumption in all unit operations

• No recycle of Thin slops in the Liquefaction

• Evaporation of thin slops without steam

• Maintaining higher solids in thick slops

• Use of 100% Syrup in Drying process

• Recycle of waste streams

• Minimum Hardware maximum efficiencies

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Specific Challenges & Opportunities

Molasses Based Plants

• Modification of distillation plant for Energy Reduction

• Reduction in effluent (spent wash or lees) at source

• Heat integration to reduce overall energy requirement

• Capacity enhancement with use of existing equipments

Effluent treatment:

• BSW Evaporation or RSW or RO Reject Evaporation

• Reduction in steam & overall energy – Additional energy is needed in BSW Degassification

• Recycle of waste streams

• Treatment of process condensate – BSW Evaporation

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Two different types of

Feed

Wet cake + Thick Slurry

Variation in feed specifications

• Inlet solids

• Different grains as feed to Distillery

• Stable unit operations (Decantation & Evaporation)

Large amount of mass

Higher Steam Consumption

Capability to handle Syrup

Higher product

temperature

Higher Back Mixing

Maintaining Nutritional

value of DDGS

Maintaining DDGS Color & Fragrance

Challenges : DDGS Drying


Content




VAPCO SOLUTIONS

BUSINESS MODEL

RECENT CASE STUDIES


Solutions from VAPCO……

MOLASSES MODULE:

• Forced circulation Reboilers for reduction in thespent wash quantity at the generation stage.

• Lower steam consumption models in distillation

• Integrated Evaporation Models with minimum addon energy for concentration of :

• RSW

• BSW

• RO Reject

• Maximum Evaporation through use of Alcoholvapours of distillation

• Process Condensate treatment

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Solutions from VAPCO……

GRAIN CONVERSION:

• Low energy cooking process

• Lower cooling water recirculation rates

• Elimination of Agitators in fermentation

• No Thin Slop recycle

• Maximum Evaporation through use of Alcohol vapours of distillation- Steam less Evaporation

• Maximization of syrup quantity being produced

• Systems to utilize 1:1 wet cake and syrup for Drying

• Lower energy requirement in the Drying systems

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Schemes Offered…..

GRAIN BASED DISTILLERY

Liquefaction Distillation Evaporation DDGS Dryer Total

Option I

Evaporator

Integrated

with

Distillation

0.3 Kg/Lit 2.7 Kg/Lit Nil 1.5 Kg/Lit 4.5 Kg/Lit

Option II

Evaporator

Integrated

with Dryer

0.3 Kg/Lit 2.2 Kg/Lit 0.3 Kg/Lit 1.5 Kg/Lit 4.3 Kg/Lit

- Option I offers flexibility in Dryer operations

- Boiler sizing in both the options will not vary significantly

- For new projects scheme needs to be chosen based on by product’s demand

- Distillation & Evaporation are must run sections & needs to be operated in case

of DWGS & DDGS.


Schemes Offered…..

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MOLASSES BASED DISTILLERY

Distillation Evaporation Total

Option I

Integrated

Evaporation Section

2.9 Kg/Lit 0.9 Kg/Lit 3.8 Kg/Lit

Option II

Stand alone

evaporation Section

2.3 Kg/Lit 2.2 Kg/Lit 4.5 Kg/Lit

- Steam & Power balance needs to be evaluated in detail. Electricity

consumption points to be estimated & evaluated

- Significant difference in the boiler sizing, but Incineration boilers are sized as

per Concentrate Qty.

- CAPEX Driven decision for New projects


Content




VAPCO SOLUTIONS

BUSINESS MODEL

RECENT CASE STUDIES


VAPCO – BUSINESS MODEL

Critical Sections Non Critical / Bought out Sections

- Basic & Detailed Engineering

- Equipment Fabrication

- Erection Services

- Commissioning Services

(Liquefaction, Distillation,Evaporation, Dryers)

- Basic Engineering

- Detailed Engineering

- Supervision of Erection

- Commissioning Services

( Milling, Silos, Fermentation,Storage, Utilities)

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VAPCO – BUSINESS MODEL

ADVANTAGES

- Process configuration with solution approach rather than

HARDWARE

- Value engineering

- Optimized Project Investment

- Optimized financial cost ( Interest Cost)

- Technically sound interface between Vendor and Client

- Increase in profitability & sustainability

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Content




VAPCO SOLUTIONS

BUSINESS MODEL

RECENT CASE STUDIES


RECENT CASE STUDIES


Key Features

- One of the largest Integrated Evaporation plant in distillery in India

- 30 Ton/hr. evaporation with Alcohol Vapours, That is “ZERO” Steam

Consumption

Value deliveredSignificant reduction in overall energy consumption with better

quality of product & By product production in Grain based Distillery

Project : 170 KLPD Total Spirit Grain based distillery

Scope of Work :

A. Design & Supply of Liquefaction Section

B. Designing of Fermentation Section

C. Modification & Technology up gradation in Distillation

plant

D. Design & Supply of Integrated Evaporation Section for

Thin slop evaporation section

Client : Bihar Distillers private limited


Key Features

- To produce Absolute alcohol as per Pharma & Aroma industry

- Customised plant design to suit existing civil structure

- Thermic fluid to be used as Heat source

Value delivered- Utility balancing as per existing infrastructure

- Compact plant with minor alterations in existing building

Project : 50 KLPD Molecular Sieve Dehydration Plant

Scope of Work :

A. Design, Engineering & Supply of MSDH plant

B. Design, engineering & Supply of SS Storage tanks as

per norms

Client : Sterling Chemicals Ltd.


Project : Process Condensate treatment to remove Ammonia & H2S

Scope of Work :

Design, Engineering & Supply of treatment plant for removal of ammonia & H2S from

Biomethanated spent wash evaporator process condensate

Features :

- First of a kind unit with simple process

- Skid mounted Unit with just 3 days installation time

- Simple &

Client : United Spirit Ltd.


Road Map Ahead……

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Value Proposition

• Plants based on International Standards

• Flexible approach

• Environment Friendly and sustainable Plants with:

– Better product quality

– Optimized Product Yields

– Lower utilities &Operating Costs

– Compact Size

Results in Sustainability & attractive paybacks34


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VAPCO Engineers Private Limited

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welcomes all delegates of upda - vapco engineers · – absolute alcohol ... –basic –detailed...

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